1. ES1050 – Introductory Engineering Design and Innovation Studio Models and Prototypes Prof. Paul Kurowski

2. Prototype definitions

3. Models and Prototypes Abstractions and simplifications of final design as needed to demonstrate, test and refine a design Physical prototypes are needed to demonstrate, test and refine a design

4. Prototype Goals

5. Types of Models/Prototypes Virtual (CAE)  CAD models  Mathematical models  Numerical models Physical  Proof-of-concept  Industrial design  Experimental  Alpha  Beta  Pre-production

6. DESIGN PROTOTYPING TESTING PRODUCTION CAD PROTOTYPING TESTING PRODUCTION CAE FEA Windows OS solid CAD TRADITIONAL PRODUCT DESIGN PROCESS SIMULATION DRIVEN PRODUCT DESIGN PROCESS affordable computers CAE tools are implemented to move design iterations from physical prototypes to virtual space of numerical (computer) models Why CAE?

8. Mathematical model Vibration of a single degree of freedom system

9. Numerical model Modes of vibration of a bracket

10. Types of Models/Prototypes Virtual (CAE)  CAD models  Mathematical models  Numerical models Physical  Proof-of-concept  Industrial design  Experimental  Alpha  Beta  Pre-production

11. Proof-of-concept Prototypes Demonstrate feasibility Simple construction Often only a part or subsystem Usually not fully functional! Not sufficient for design validation! http://me118.stanford.edu/pictures/Win01Projects/TooShort/images/2nd%20prototype.JPG

12. Industrial Design Prototype How will the product look and feel? Simple materials (foam, wood, etc.) Usually non-functional http://www.linternaute.com/auto/mondial-automobile-concept-car/audi-rsq3.jpg

13. 1962 Prototype of Lunar Module Industrial Design Prototype

14. 1969 Lunar Module http://www.lpi.usra.edu/expmoon/Apollo16/A16_LanderFS.gif

15. Experimental Prototype Intended for physical experiments and testing Often only a subsystem Prototype of shock-absorbing caster Test results

16. Alpha Prototype Include most but not all functions of the final design Answer questions about overall layout of the design http://drwho.virtadpt.net/pictures/memorial-day-2004/apple-prototype.jpg

17. Beta Prototype Fully functional prototype Final product form Purpose is final testing Different manufacturing processes used  Machining rather than injection molding  Made by hand

18. Pre-Production Prototype Made using final production processes and tooling Identical to the final product Used to fine-tune the production process Pre-production Prototype http://www.dpreview.com/articles/canoneos5d/

19. Prototype Goals Answer simple questions (e.g. will an idea work?) Obtain feedback from customers Aid in visualization Realistic models for marketing and advertising Study the “look and feel” of the product Functional testing and evaluation

20. Prototype Construction in ES1050 Inexpensive Easy No special tools Quick http://www.ben.com/LEGO/rcx/picoscout/breadboard.jpg

21. Common Prototyping Materials in ES1050 Wood Plastic  Plexiglass Cardboard and paper Metal http://www.riscx.com/pyramac/proto_pics/proto_3_600.jpg

22. Prototyping Tools in ES1050 Simple hand tools  Scissors  Screwdrivers  Wrenches Simple joining methods  Glue  Duct tape  Screws http://www.someoftheanswers.com/pictures/visions/duct_tape_bike.jpg

23. Construction kits you may want to use in ES1050 Lego Meccano Others http://www.sentex.net/~mwandel/legos/legos.html

24. Lego Many mechanical and electrical parts Inexpensive and easy No tools required http://www.hamster.dk/~purple/robot/iBOT/lego_robot_prototype.jpg http://www.cs.rhul.ac.uk/eca/micromouse/lego/shakey/images/parts.jpg

25. Meccano Uses metal parts Simple tools www.meccano.com http://webperso.easyconnect.fr/esteve.jeanmax/j.e.o/fotopi%E8ces/MarklinPiecP.jpg

26. Rapid Prototyping is available to ES1050 Creates a physical prototype directly from a CAD model Can include color Uses low-strength materials www.zcorp.com

27. Rapid Prototyping www.zcorp.com

28. Rapid Prototyping

29. Types of prototypes commonly used in ES1050

30. ES050 Prototypes in 2006/2007 when the main Design Project was: Demonstrate a Scientific Principle